233_41860_001_g_d14_i35_i36_summ

April/07/05 W.O. # 233.41860.001.G1

Template Revision: 1

Revision Date: 01/01/05

Work Order: 233.41860.001.G

FEA Design Level #: 14

Load Case Iteration #: 35,36

Analyst (Employer): Ashish (Altair)

ANALYSIS RESULTS SUMMARY:Toyota Tundra 20% Front SeatFMVSS 207/210 – April-07-05

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Seat: Toyota Tundra 20% Front SeatLoad Case: FMVSS 207/210

FEA Design Level #: 14 Load Case Iteration #: 35,36

I. Conclusions and RecommendationsDesign 14 Iteration 35

• The Toyota Tundra 20% front seat withstands the 207/210 load case.

• No structural failure observed under the 207/210 load case.

• Maximum torque on right side recliner is 2888 Nm, where as maximum torque on left side recliner is 1045 Nm.

Design 14 Iteration 36• The Toyota Tundra 20% front seat withstands the 207/210 load case.

• No structural failure observed under the 207/210 load case.

• Maximum torque on right side recliner is 2266 Nm, where as maximum torque on left side recliner is 912 Nm.

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II. Design Level and Model DescriptionDesign Level 14 and Iteration 35From the design 14 Iter 32 model: following changes has been done1) CG loading change as per New FMVSS with distribution bar . 2) Lap block change to narrow mga lap block.

L-shaped steel channel 40x40xt4.

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II. Design Level and Model DescriptionDesign Level 14 and Iteration 36From the design 14 Iter35 model: following changes has been done1) The shoulder and lap belt load reduce to 100% of FMVSS standard (from 120%). (13500N) 2) The CG load reduce to 100% of FMVSS standard (from 120%).(3551 N)

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Design 14:

Welds between outer and inner RH cushion bracket added as per design11 iteration 19.

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Material and Thickness information for Major Components

Design 14 Iteration 35

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Belt routing over retractor mtg. bracket, back tube and wire belt exit

Retractor mounting bracket

Back tube

2-D seat belt

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III. Detailed Analysis Results

Deformed Shape of Seat Deformation plot with un-deformed geometry

Pictures shown after structure is stabilized at 100% loading.

FMVSS 207/210 load results


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III. Detailed Analysis Results

Deformed Shape of Seat Deformation plot with un-deformed geometry

Pictures shown after structure is stabilized at 100% loading.



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Resultant Deflection contour


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X-Component Z-Component


X and Z Deflection contour


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The von Mises stress contour of complete seat

Contour shown at stabilized timeDesign 14 Iteration 35

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The effective plastic strain contour of complete seat


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Resultant Deflection contour


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X-Component Z-Component


X and Z Deflection contour


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The von Mises stress contour of complete seat


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The effective plastic strain contour of complete seat


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Analysis Outputs Under FMVSS Loading, Steady-State Conditions - Belt tensions at the attachment points

Lap beltLH side 16626 N

RH side 8890 N

Shoulder belt Upper Shoulder Belt Tension (Belt Exit Point) 8231 N


Lap beltLH side 13781 N

RH side 7751 N

Shoulder belt Upper Shoulder Belt Tension (Belt Exit Point) 7118 N


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Maximum Bolt forces at floor mounting locations

LH cushion front

A = 34625 SR = 4023.27

RH cushion front

A = 42071 SR = 5531.42

LH cushion rear

A = 49586.4 SR = 12842

RH cushion rear

A = 39044 SR = 10710


A = axial force, SR = shear resultant

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LH cushion front

A =33398.3 SR = 3828.51

RH cushion front

A = 38835 SR = 4800

LH cushion rear

A = 46537 SR = 11745

RH cushion rear

A = 36771 SR = 10061.3

Maximum Bolt forces at floor mounting locations


A = axial force, SR = shear resultant

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Generic JCI shoulder clevis

Generic JCI shoulder block

IV. Test Set-up and Acceptance Criteria

Belt exit point

CG bars

Generic JCI lap block

Note: The “narrow mga lap block” is used for the center lap block

Retractor mounting point.

Design 14 Iteration 35,36

Load Distribution bar

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• Seatback in design position.

• Load levels shown are at FMVSS+ 20% (16200N). In the analysis, the applied loads are held FMVSS + 20% load level.

• The shoulder and lap belt loading =13500x1.2=16200 N

• The CG loading =(20xgxmass)x1.2=(20x9.81x18.1 kg)x1.2=4261 N

16200 N

Acceptance Criteria:

• Seat must hold FMVSS + 20% loads without any part fracture.

4261 N


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• Seatback in design position.

• Load levels shown are at FMVSS (13500N). In the analysis, the applied loads are held FMVSS.

• The shoulder and lap belt loading =13500 =13500 N

• The CG loading = 20xgxmass= 20x9.81x18.1 kg = 3551 N

13500 N

Acceptance Criteria:

• Seat must hold FMVSS loads without any part fracture.

3551 N


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V. Analysis Methods Summary

JCI Analysis MethodRevision

LevelComments/Exceptions

207/210 General Analysis Procedure

(207210_Analysis_Procedure.pdf)

1(1/1/05)

207/210 Body Block Positioning Procedure

(Belt_Lengths_and_Body_Block_Positioning_Procedure.pdf)

1(1/1/05)

Dyna General Procedure (Dyna_General.pdf)

1(1/1/05)

Forming Mapping Procedure (Mapping_Forming_Results.pdf)

1(1/1/05)

Material Property Curves 0(10/1/04)

Detailed Bolt Modeling Macro 2(01/21/05)

The following standardized JCI methods were used for this analysis iteration(s):

233_41860_001_g_d14_i35_i36_summ

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